CN108394133A - 非氧化物热保护系统和生产用于制造其的复合材料的方法 - Google Patents

非氧化物热保护系统和生产用于制造其的复合材料的方法 Download PDF

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Publication number
CN108394133A
CN108394133A CN201711255893.4A CN201711255893A CN108394133A CN 108394133 A CN108394133 A CN 108394133A CN 201711255893 A CN201711255893 A CN 201711255893A CN 108394133 A CN108394133 A CN 108394133A
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CN
China
Prior art keywords
layer
protection system
thermal protection
thermal
porous low
Prior art date
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Pending
Application number
CN201711255893.4A
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English (en)
Inventor
V·亨
W·W·陈
L·L·莱曼
P·J·莫博思
M·E·萨勒玛
T·R·平尼
J·D·恩伯
D·E·尼迈耶
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Boeing Co
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Boeing Co
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Publication date
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Publication of CN108394133A publication Critical patent/CN108394133A/zh
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Abstract

本发明涉及非氧化物热保护系统和生产用于制造其的复合材料的方法。提供了用于交通工具子结构的热保护系统(200)。该热保护系统(200)包括用于保护交通工具子结构的外层(210)。该热保护系统(200)进一步包括用于贴合至交通工具子结构(108)的内层(220)。该热保护系统(200)还包括夹在内层和外层(210、220)之间的隔热层(230)。该隔热层(230)包括具有致密化部分(232)的多孔低密度陶瓷隔热材料，该致密化部分(232)覆盖外层(210)的内表面以增强粘着力。

Description

非氧化物热保护系统和生产用于制造其的复合材料的方法
技术领域
本申请涉及用于交通工具的热保护系统，并且具体地涉及刚化混合隔热非氧化物(RHINO)热保护系统和生产用于制造高速交通工具——比如高速攻击武器——的刚化混合隔热非氧化物热保护系统的非氧化物陶瓷复合材料的方法。
背景技术
高速交通工具的典型热保护系统包括许多材料层。材料层可以包括夹在外层和内层之间的隔热层，该内层贴合至高速交通工具的子结构的表面。作为已知的热保护系统的实例，隔热层包括相对刚性材料，比如相对低密度纤维陶瓷材料。外层包括基本上刚性的和相对薄的构件，该构件具有相对高的耐热性和相对高的结构耐久性，比如陶瓷基体复合材料。内层包括有回弹力可压缩材料，其具有相对低的剪切刚度或相对低的拉伸刚度。当外层在交通工具子结构上时，内层抵靠交通工具子结构被压缩地预负荷。提供用于高速交通工具——比如高速攻击武器——的改进的热保护系统将是期望的。
发明内容
在一方面，提供了用于交通工具子结构的热保护系统。该热保护系统包括用于保护交通工具子结构的外层。该热保护系统进一步包括用于贴合至交通工具子结构的内层。该热保护系统还包括夹在内层和外层之间的隔热层。该隔热层包括具有致密化部分的多孔低密度陶瓷隔热材料，该致密化部分覆盖外层的内表面以增强粘着力。
在另一方面，提供了用于交通工具子结构的热保护系统。该热保护系统包括外刚性层，该外刚性层包括非氧化物陶瓷复合材料——比如碳纤维增强的碳化硅——的薄蒙皮层，用于保护交通工具子结构。该热保护系统进一步包括贴合至交通工具子结构的内共形层(conformal layer)。该热保护系统还包括夹在内层和外层之间的刚性陶瓷隔热层。该隔热层包括具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷材料。
在又另一方面，提供了生产用于制造交通工具子结构的刚化混合隔热非氧化物热保护系统的非氧化物陶瓷复合材料的方法。该方法包括形成具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷隔热材料的层为期望的尺寸和形状。该方法进一步包括使多孔低密度陶瓷隔热材料的层的层部分致密化以形成具有在大约24lbs/ft3和50lbs/ft3之间的密度的致密化层部分。该方法还包括共处理多层致密化层部分至非氧化物陶瓷复合材料——比如碳纤维增强的碳化硅——的薄蒙皮层上。该方法进一步包括利用共形材料(conforming material)层覆盖多孔低密度陶瓷隔热材料的层的内表面。
其它方面将从下面的具体实施方式、附图和所附权利要求书变得显而易见。
附图说明
图1是分解透视图，其仅以截面显示了由根据实例实施方式构建的刚化混合隔热非氧化物(RHINO)热保护系统包围的高速交通工具的子结构的一些部分。
图2是图1的一部分的放大视图，并且显示RHINO热保护系统的材料层的横截面。
图3是流程图，其描绘了生产用于制造图1和2的RHINO热保护系统的非氧化物陶瓷复合材料的实例方法。
具体实施方式
本公开内容涉及刚化混合隔热非氧化物(RHINO)热保护系统和生产用于制造刚化混合隔热非氧化物(RHINO)热保护系统的非氧化物陶瓷复合材料的方法。该热保护系统的具体构造和实施该热保护系统的工业可以改变。将理解，下面的公开内容提供了用于实施各种实施方式的不同特征的许多实施方式或实例。描述了部件和布置的具体实例以简化本公开内容。这些仅仅是实例并且不意欲是限制性的。通过实例的方式，下面的公开内容描述了用于保护高速交通工具——比如高速攻击武器——的RHINO热保护系统。该RHINO热保护系统可以由制造热保护系统的原始设备制造商(OEM)按照军事和空间条例实施。参照图1，图解了由根据实例实施方式构建的RHINO热保护系统包围的实例高速交通工具100的分解透视图。图1的分解透视图仅以截面显示了一些部分。高速交通工具100包括在后圆锥体部分104和头部尖端(nose tip)106之间布置的前圆锥体部分102。
头部尖端106可以包括钨材料。后圆锥体部分104具有可以包括钛材料的肋形子结构108。钛肋形子结构108被布置在也可以包括钛材料的隔板110的前面。后圆锥体部分104具有大约36英寸(91.44厘米)的长度，并且前圆锥体部分102具有大约16英寸(40.64厘米)的长度。热保护系统200被布置在前圆锥体部分102和后圆锥体部分104上。
参照图2，图解了图1的一部分(在图1中以数字“2”表示)的放大视图。图2的放大视图显示了RHINO热保护系统200的材料层的横截面。热保护系统200包括用于保护交通工具100的子结构(例如，前圆锥体部分和后圆锥体部分102、104)的外层210。热保护系统200进一步包括用于贴合至交通工具子结构的内层220。热保护系统200还包括夹在内层和外层210、220之间的隔热层230。隔热层230包括具有致密化部分232的多孔低密度陶瓷隔热材料，该致密化部分232覆盖外层210的内表面212以增强粘着力并促进与外层210的相容性。
在图1和2中示出的实例实施方式中，外层210包括用于保护交通工具子结构的碳纤维增强的碳化硅(C-SiC)的薄蒙皮刚性层。C-SiC的薄蒙皮层210具有在大约0.04英寸(0.102厘米)和大约0.08英寸(0.203厘米)之间的厚度。C-SiC的薄蒙皮层210具有大约百万分之1.65/华氏度(ppm/°F)的热膨胀系数。在一些实施方式中，外层210包括陶瓷纤维增强的非氧化物陶瓷基体复合材料——比如碳-碳化硅、碳化硅-碳化硅、碳-碳化铪、碳-硼化铪、碳-氮化硅——的薄蒙皮层，其具有在大约0.04英寸(0.102厘米)和大约0.08英寸(0.203厘米)之间的厚度。
内层220的实例包括用于贴合至交通工具子结构108的硅树脂的共形层222。共形硅树脂的层222与覆盖隔热层230的内表面234的室温硫化(RTV)硅树脂224结合。共形硅树脂的层222具有大约0.25英寸(0.635厘米)的厚度。RTV硅树脂224具有大约0.01英寸(0.025厘米)的厚度。在一些实施方式中，内层220包括共形材料——比如硅树脂——的层或者覆盖隔热层230的内表面的应变隔离垫。在一些实施方式中，共形材料的层粘附地结合至隔热层230。
隔热层230具有大约一英寸(2.54厘米)的厚度。隔热层230的多孔低密度陶瓷材料是刚性的并且具有在大约12磅每立方英尺(lbs/ft3)和25lbs/ft3之间的密度。隔热层230具有大约1.58ppm/°F的热膨胀系数。致密化部分232具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度。
外层、内层和隔热层210、220、230的组合配合以使得热保护系统200能够经受高达或高于3000°F的温度而不导致热保护系统200的退化，同时维持交通工具子结构在或低于其最大承温能力。
下列实例阐明了生产用于制造根据实施方式的热保护系统200的非氧化物陶瓷复合材料的方法。实例方法意欲阐明，但绝不限制本发明的范围。
参照图3，流程图300描绘了生产用于制造在图1和2中示出的实例RHINO热保护系统200的实例非氧化物陶瓷复合材料的实例方法。在方框302中，多孔低密度陶瓷隔热材料的层被形成为(例如，机器加工为)期望尺寸和形状(即，最终尺寸和形状)。实例多孔低密度陶瓷隔热材料商业可获得为来自位于Huntington Beach,CA的波音公司的产品型号HBMS-36-021-01。可以使用的其它多孔低密度陶瓷隔热材料，比如碳或碳化硅泡沫是可能的。该方法然后进行至方框304。
在方框304中，多孔低密度陶瓷隔热材料的层的层部分232被致密化以形成多层致密化层部分。在一些实施方式中，层部分232通过陶瓷浆料渗透(ceramic slurryinfiltration)和后固化，接着预陶瓷树脂渗透(pre-ceramic resin infiltration)和热解以闭合多孔性而被致密化，并且从而形成多层致密化层部分。在一些实施方式中，多孔低密度陶瓷隔热材料经历重复热解和利用聚合树脂重复涂布以去除结构多孔性从而形成致密化层部分232。在一些实施方式中，致密化层部分232具有在大约24lbs/ft3和50lbs/ft3之间的密度。
然后，在方框306中，来自方框304的致密化层部分232被共处理至非氧化物陶瓷复合材料——比如C-SiC——的薄蒙皮层210上。更具体地，致密化层部分232被共处理至C-SiC的薄蒙皮层210上，其通过将C-SiC的薄蒙皮层210原位处理至致密化层部分232上并且使C-SiC的薄蒙皮层210经历利用聚合树脂的重复渗透和重复热解，从而形成完全致密化的C-SiC的薄蒙皮层210。而且，如方框308中所示出的，多孔低密度陶瓷隔热材料的层的内表面覆盖有与RTV硅树脂224结合的共形材料的层222。该方法然后结束。
根据上述实例方法生产的非氧化物陶瓷复合材料适合用于制造任何热保护系统，比如在图1和2中示出的实例热保护系统200。具体而言，生产的非氧化物陶瓷复合材料可以被用于制造高速交通工具应用的热保护系统。
应当显而易见的是，提供了集成的混合材料热保护系统用于高速交通工具，比如高速攻击武器，例如。该热保护系统可以适合冷交通工具子结构或者热交通工具子结构。共形材料(conformal material)的层部分地隔离多孔低密度陶瓷隔热材料层和薄的非氧化物陶瓷复合材料蒙皮使得热保护系统“浮”在交通工具子结构上。而且，非氧化物陶瓷复合材料——比如C-SiC——的薄蒙皮层的热膨胀系数(即，在上面的实例实施方式中的大约1.65ppm/°F)和隔热层的热膨胀系数(即，在上面的实例实施方式中的大约1.58ppm/°F)密切匹配。这在升高温度下以低应力提供了隔热层和C-SiC的薄蒙皮层之间的良好结合。
结果是当热保护浮在交通工具子结构上时具有处理3000°F的温度而不导致热保护系统退化的能力的轻质热保护系统(与现有技术的热保护系统相比)。另一个结果是与包括非氧化物陶瓷基体复合材料夹层配置的热保护系统相比相对更易于制造的热保护系统。
还应当显而易见的是，集成的混合材料热保护系统消除了对于厚的层压制品的需要。例如，薄的C-SiC蒙皮通过下面的低密度隔热层和交通工具子结构被稳定。这提供了不需要额外硬化的以阻止在气动热负载、声负载或机械负载下的弯曲的半结构性壳体。而且，共形层使交通工具子结构与低密度隔热材料和薄的C-SiC蒙皮的半结构性壳体之间的负载路径分离。结果是不仅具有耐高温能力和低重量，而且具有优异的隔热性能、良好的强度和耐损伤的半结构性壳体。
虽然上述说明描述了实例非氧化物陶瓷复合材料和根据军事和空间条例生产OEM的非氧化物陶瓷复合材料的实例方法，但是可以想到的是实例非氧化物陶瓷复合材料和方法可以根据可适用的工业标准在任何工业中实施。
进一步地，本公开内容包括根据下列条款的实施方式：
条款1.用于交通工具子结构的热保护系统，该热保护系统包括：
用于保护交通工具子结构的外层；
用于贴合至交通工具子结构的内层；和
夹在内层和外层之间的隔热层，其中该隔热层包括具有致密化部分的多孔低密度陶瓷隔热材料，该致密化部分覆盖外层的内表面以增强粘着力。
条款2.根据条款1的热保护系统，其中多孔低密度陶瓷隔热材料的致密化部分具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度。
条款3.根据条款1的热保护系统，其中外层包括陶瓷纤维增强的非氧化物陶瓷基体复合材料——比如碳-碳化硅、碳化硅-碳化硅、碳-碳化铪、碳-硼化铪、碳-氮化硅——的薄蒙皮层，其具有在大约0.04英寸(0.102厘米)和大约0.08英寸(0.203厘米)之间的厚度。
条款4.根据条款1的热保护系统，其中外层具有大约1.65ppm/°F的热膨胀系数。
条款5.根据条款4的热保护系统，其中隔热层具有大约1.58ppm/°F的热膨胀系数。
条款6.根据条款5的热保护系统，其中(i)内层包括共形材料比如硅树脂的层或者覆盖隔热层的内表面的应变隔离垫，和(ii)外层、内层和隔热层的组合配合以使得热保护系统能够经受高达或高于3000°F的温度而不导致热保护系统的退化，同时维持交通工具子结构在或低于其最大承温能力。
条款7.根据条款6的热保护系统，其中共形材料的层粘附地结合至隔热层。
条款8.用于交通工具子结构的热保护系统，该热保护系统包括：
用于保护交通工具子结构的外刚性层，其包括非氧化物陶瓷复合材料的薄蒙皮层；
贴合至交通工具子结构的内共形层；和
夹在内层和外层之间的刚性陶瓷隔热层，其中该隔热层包括具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷材料。
条款9.根据条款8的热保护系统，其中非氧化物陶瓷复合材料的薄蒙皮层包括具有大约1.65ppm/°F的热膨胀系数的碳纤维增强的碳化硅层。
条款10.根据条款9的热保护系统，其中刚性陶瓷隔热层具有大约1.58ppm/°F的热膨胀系数。
条款11.根据条款10的热保护系统，其中(i)多孔低密度陶瓷隔热材料包括致密化部分，其覆盖碳纤维增强的碳化硅层的内表面以增强与碳纤维增强的碳化硅层的粘着力，和(ii)外层、内层和隔热层的组合配合以使得热保护系统能够经受高达或高于3000°F的温度而不导致热保护系统的退化，同时维持交通工具子结构在或低于其最大承温能力。
条款12.根据条款11的热保护系统，其中多孔低密度陶瓷隔热材料的致密化部分具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度。
条款13.根据条款12的热保护系统，其中内共形层与室温硫化(RTV)硅树脂结合并且覆盖隔热层的内表面。
条款14.根据条款8的热保护系统，其中(i)多孔低密度陶瓷隔热材料包括致密化部分，其覆盖碳纤维增强的碳化硅层的内表面以增强与碳纤维增强的碳化硅层的粘着力，和(ii)外层、内层和隔热层的组合配合以使得热保护系统能够经受高达或高于3000°F的温度而不导致热保护系统的退化，同时维持交通工具子结构在或低于其最大承温能力。
条款15.根据条款14的热保护系统，其中多孔低密度陶瓷隔热材料的致密化部分具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度。
条款16.根据条款15的热保护系统，其中碳纤维增强的碳化硅层具有在大约0.04英寸(0.102厘米)和大约0.08英寸(0.203厘米)之间的厚度。
条款17.生产用于制造交通工具子结构的刚化混合隔热非氧化物热保护系统的非氧化物陶瓷复合材料的方法，该方法包括：
形成具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷隔热材料的层至期望尺寸和形状；
使多孔低密度陶瓷隔热材料的层的层部分致密化以形成具有在大约24lbs/ft3和50lbs/ft3之间的密度的多层致密化层部分；
共处理多层致密化层部分至非氧化物陶瓷复合材料的薄蒙皮层上；和
利用共形材料的层覆盖多孔低密度陶瓷隔热材料的层的内表面。
条款18.根据条款17的方法，其中使多孔低密度陶瓷隔热材料的层的层部分致密化包括使该层部分经历陶瓷浆料渗透和后固化，接着预陶瓷树脂渗透和热解以闭合多孔性并且从而形成多层致密化层部分。
条款19.根据条款17的方法，其中使多孔低密度陶瓷隔热材料的层的层部分致密化包括使该层部分致密化以形成具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度的多层致密化层部分。
条款20.根据条款17的方法，其中利用共形材料的层覆盖多孔低密度陶瓷隔热材料的层的内表面包括利用与室温硫化(RTV)硅树脂结合的共形硅树脂层覆盖多孔低密度陶瓷隔热材料的层。
虽然已经显示并描述了公开的实施方式的各个方面，但是本领域技术人员在阅读说明书之后可以想到改变。本申请包括这种改变并且仅由权利要求书的范围所限制。

Claims (13)

1.一种用于交通工具子结构(108)的热保护系统(200)，所述热保护系统(200)包括：
用于保护所述交通工具子结构(108)的外层(210)；
用于贴合至所述交通工具子结构(108)的内层(220)；和
夹在所述内层和外层(210、220)之间的隔热层(230)，其中所述隔热层(230)包括具有致密化部分(232)的多孔低密度陶瓷隔热材料，所述致密化部分(232)覆盖所述外层(210)的内表面(212)以增强粘着力。
2.根据权利要求1所述的热保护系统(200)，其中所述多孔低密度陶瓷隔热材料的所述致密化部分(232)具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度。
3.根据权利要求1所述的热保护系统(200)，其中所述外层(210)包括陶瓷纤维增强的非氧化物陶瓷基体复合材料——比如碳-碳化硅、碳化硅-碳化硅、碳-碳化铪、碳-硼化铪、碳-氮化硅——的薄蒙皮层，其具有在大约0.04英寸(0.102厘米)和大约0.08英寸(0.203厘米)之间的厚度。
4.根据权利要求1所述的热保护系统(200)，其中所述外层(210)具有大约1.65ppm/°F的热膨胀系数。
5.根据权利要求4所述的热保护系统(200)，其中所述隔热层(230)具有大约1.58ppm/°F的热膨胀系数。
6.根据权利要求1-5中任一项所述的热保护系统(200)，其中(i)所述内层(220)包括共形材料——比如硅树脂——的层(222)或者覆盖所述隔热层(230)的内表面(234)的应变隔离垫，和(ii)外层、内层和隔热层(210、220、230)的组合配合以使得所述热保护系统(200)能够经受高达或高于3000°F的温度而不导致所述热保护系统(200)的退化，同时维持所述交通工具子结构在或低于其最大承温能力。
7.根据权利要求6所述的热保护系统(200)，其中所述共形材料的层(222)粘附地结合至所述隔热层(230)。
8.根据权利要求1所述的热保护系统(200)，其中所述隔热层(230)包括具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷材料。
9.根据权利要求6所述的热保护系统(200)，其中所述共形材料的层(222)与室温硫化(RTV)硅树脂(224)结合并且覆盖所述隔热层(230)的内表面。
10.一种生产用于制造交通工具子结构(108)的刚化混合隔热非氧化物热保护系统(200)的非氧化物陶瓷复合材料的方法，所述方法包括：
形成具有在大约12lbs/ft3和25lbs/ft3之间的密度的多孔低密度陶瓷隔热材料的层至期望尺寸和形状；
使所述多孔低密度陶瓷隔热材料的层的层部分致密化以形成具有在大约24lbs/ft3和50lbs/ft3之间的密度的多层致密化层部分；
共处理所述多层致密化层部分至非氧化物陶瓷复合材料的薄蒙皮层上；和
利用共形材料的层(222)覆盖所述多孔低密度陶瓷隔热材料的层的内表面(234)。
11.根据权利要求10所述的方法，其中使所述多孔低密度陶瓷隔热材料的层的层部分致密化包括使所述层部分经历陶瓷浆料渗透和后固化，接着预陶瓷树脂渗透和热解以闭合多孔性并且从而形成所述多层致密化层部分。
12.根据权利要求10所述的方法，其中使所述多孔低密度陶瓷隔热材料的层的层部分致密化包括使所述层部分致密化以形成具有在大约0.10英寸(0.254厘米)和大约0.20英寸(0.508厘米)之间的厚度的所述多层致密化层部分。
13.根据权利要求10-12中任一项所述的方法，其中利用共形材料的层(222)覆盖所述多孔低密度陶瓷隔热材料的层的内表面(234)包括利用与室温硫化(RTV)硅树脂(234)结合的共形硅树脂层覆盖所述多孔低密度陶瓷隔热材料的层。
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